Heating device for a heating and sealing system

ABSTRACT

A protective packaging formation device is disclosed herein. The device includes an inflation assembly that directs fluid between first and second overlapping plies of a web material. The device also includes a sealing mechanism that includes an arcuate web-support surface. The web-support surface includes a heater that defines a heating zone that is operable to heat the plies to create a longitudinal heat seal that seals the first and second plies together as the web is driven over the heating zone in a downstream direction. The web-support surface also includes a cooling zone disposed downstream of the heating zone operable to allow the heated plies to cool at the longitudinal heat seal as the web is driven over the heating zone in a downstream direction, such that the cooled longitudinal heat seal retains the fluid between the plies.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Application No.62/630,766 filed on Feb. 14, 2018, entitled “Heating Device for Heatingand Sealing System”, which is hereby incorporated by reference in itsentirety.

TECHNICAL FIELD

The present disclosure relates to packaging materials. Moreparticularly, the present disclosure is directed to devices and methodsfor manufacturing inflatable cushions to be used as packaging material.

BACKGROUND

A variety of inflated cushions are well known and used for sundrypackaging applications. For example, inflated cushions are often used asprotective packaging in a manner similar to or in place of foam peanuts,crumpled paper, and similar products. Also for example, inflatedcushions are often used as protective packaging in place of molded orextruded packaging components. A typical type of inflated cushions isformed from films having two plies that are joined together by seals.The seals can be formed simultaneously with inflation, so as to captureair therein, or prior to inflation to define a film configuration havinginflatable chambers. The inflatable chambers can be inflated with air oranother gas and thereafter sealed to inhibit or prevent release of theair or gas.

In the process of inflating and sealing the chambers, the films aresealed by a variety of heating apparatuses. In traditional systems, thetemperatures and pressures on the seals are not sufficiently controlledafter the seal is made. Poor post seal control leads to increasedpackaging failure. Specifically, traditional machines pass the webmaterial off the heating element and remove the compressive forcesbefore cooling is complete. As such, improved heating and cooling pathsand protection for the seal are therefore desirable.

SUMMARY

Embodiments of the present disclosure may include a protective packagingformation device. The device may include an inflation assembly thatdirects fluid between first and second overlapping plies of a webmaterial. The device may include a sealing mechanism that includes anarcuate web-support surface. The web-support surface includes a heaterthat defines a heating zone that is operable to heat the plies to createa longitudinal heat seal that seals the first and second plies togetheras the web is driven over the heating zone in a downstream direction. Acooling zone disposed downstream of the heating zone is operable toallow the heated plies to cool at the longitudinal heat seal as the webis driven over the heating zone in a downstream direction, such that thecooled longitudinal heat seal retains the fluid between the plies. Thedevice may include a driving mechanism that drives the film in thedownstream direction over the heating and cooling zones, with the websupported by the web-support surface from an upstream location to adownstream location. The heating zone of the web-support surface may bedisposed offset towards the upstream location.

In accordance with various embodiments, the inflation assembly has anozzle insertable between the plies to direct the fluid between theplies, wherein the driving mechanism directs the web over the nozzle inthe downstream direction. The heating and cooling zone may have anarcuate profile. The arcuate profile may be convex. The heat zone may bebetween 25 and 75% of the pinch zone longitudinal length. The coolingzone may be between 25 and 75% of the pinch zone. The driving mechanismcomprises a belt that holds the web against the arcuate profile defininga pinch zone.

In accordance with various embodiments, the heater can be a thin filmheater that follows the web-support surface. The sealing mechanism mayinclude a heater support having two electrically conductive supports andan electrically insulative support between the conductive supports. Theconductive and insulative supports may cooperatively forming theweb-support surface for the web with the thin film heater extending fromone electrically conductive support to the other. The insulative supportmay extend for more than half of the pinch zone and the heat zone iscenter on and may extend for more than half of the web-support surfacethat is defined by the insulative support.

Embodiments of the present disclosure may include a protective packagingformation device. The device may include an inflation assembly thatdirects fluid between first and second overlapping plies of a webmaterial. The device may include a sealing mechanism. The sealingmechanism may include a heater support having two electricallyconductive supports and an electrically insulative support between theconductive supports. The conductive and insulative supports maycooperatively form a support surface for the web. The device may includea heating zone defined by a first portion of the support surface andoperable to heat the plies to create a longitudinal heat seal that sealsthe first and second plies together as the web is driven over theheating zone in a downstream direction.

Embodiments of the present disclosure may include a cooling zonedisposed downstream of the heating zone along a second portion of thesupport surface and operable to allow the heated plies to cool at thelongitudinal heat seal as the web is driven over the heating zone in adownstream direction, such that the cooled longitudinal heat sealretains the fluid between the plies. A driving mechanism may be includedto drive the film in the downstream direction over the heating andcooling zones, with the web supported by the web-support surface from anupstream location to a downstream location.

The device may include a heating element electrically connected to bothconductive supports such that the heating element is supported by theconductive and insulative supports, wherein the heating element includesa heating zone disposed over and supported by the insulative support.The support surface may be arcuate. The support surface is substantiallycontinuous from an upstream one of the conductive supports over theinsulative support and over a downstream one of the conductive supports.The heating zone may be offset towards the upstream portion of theweb-support surface along the pinch zone. The sealing mechanism includesa compression element that opposes the support surface, which forms asubstantially stationary surface against which the web material ispressured by the opposing compression element. The opposing compressionmember may be a belt that forms a portion of the drive mechanism. Aheater may extend from one electrically conductive support to the otherand is electrically connected to each. The heater may be a thin filmheater that follows the support surface. The thin film may include ahigh heat zone that is laid over the insulating member and a low heatzone located along at least one of the electrically conductive supports.The heat zone may be defined by a length of the thin film heater thathas a first longitudinal portion with a reduced cross-section thatoutputs sufficient heat to heat seal the web material and a secondlongitudinal portion wider than the first longitudinal portion having areduced heat output and configured to gradually cool the sealed webmaterial.

In accordance with various embodiments, at least one of the electricallyconductive supports includes a tension lever that rotates relativethereto. A thin film heater may be connected to the tension lever, whichplaces a biasing force away from the opposing connection of the thinfilm heater keeping the thin film heater in tension around the supportsurface. The web may be separated from the heater by at least one of alow friction belt or a low friction barrier.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of an uninflated material web;

FIGS. 2-4 are a rear perspective view, a proximal-side view, and a frontperspective view, respectively, of an inflation and sealing device;

FIGS. 5 and 6 are a front perspective view and a proximal-side view,respectively, thereof with the covers removed;

FIG. 7 is a cross-sectional view taken along section VI-VI show in FIG.6;

FIG. 8A is a perspective view of a heating assembly of the inflation andsealing system of FIG. 2;

FIG. 8B is a perspective view thereof with an insulator block removedfor clarity;

FIG. 8C is a distal side view of the heating assembly of FIG. 8A;

FIG. 8D is a proximal side view thereof;

FIG. 8E is a bottom view thereof;

FIG. 8F is a flat view of a heating element of FIG. 8A;

FIGS. 9A and 9B are a rear perspective view and a proximal-side view,respectively, thereof of another embodiment of the heating and sealingassembly; and

FIGS. 9C and 9D are a rear view and a proximal-side view, respectively,thereof of another embodiment of the heating and sealing assembly.

DETAILED DESCRIPTION

The present disclosure is related to protective packaging and systemsand methods for converting inflatable material into inflated cushionsthat may be used as cushioning or protection for packaging and shippinggoods.

As shown in FIG. 1, a multi-ply flexible web material 100 for inflatablecushions 121 is provided. The web material 100 includes a first film ply105 having a first longitudinal edge 102 and a second longitudinal edge104, and a second film ply 107 having a first longitudinal edge 106 anda second longitudinal edge 108. The second ply 107 is aligned to be overlapping and can be generally coextensive with the first ply 105, i.e.,at least respective first longitudinal edges 102, 106 are aligned witheach other and/or second longitudinal edges 104, 108 are aligned witheach other. In some embodiments, the plies can be partially overlappingwith inflatable areas in the region of overlap.

FIG. 1 illustrates a top view of the web material 100 having first andsecond plies 105, 107 joined to define a first longitudinal edge 110 anda second longitudinal edge 112 of the web material 100 (also referred toas film 100). The first and second plies 105, 107 can be formed from asingle sheet of flexible material, a flattened tube of flexible materialwith one edge having a slit or being open, or two sheets of flexiblematerial which may be sealed along the longitudinal edges 104, 108 todefine the longitudinal edge 112 of the flexible structure 100. Forexample, the first and second plies 105, 107 can include a single sheetof flexible material that is folded to define the joined second edges104, 108 (e.g., “c-fold film”). In a more particular example, edges 104,108 are at the c-fold in such an embodiment. Alternatively, for example,the first and second plies 105, 107 can include a tube of flexiblematerial (e.g., a flatten tube) that is slit along the aligned firstlongitudinal edges 102, 106. Also, for example, the first and secondplies 105, 107 can include two independent sheets of flexible materialjoined, sealed, or otherwise attached together along the aligned secondedges 104, 108.

The web material 100 can be formed from any of a variety of flexible webmaterials known to those of ordinary skill in the art. Such webmaterials include, but are not limited to, ethylene vinyl acetates(EVAs), metallocenes, polyethylene resins such as low densitypolyethylene (LDPE), linear low density polyethylene (LLDPE), and highdensity polyethylene (HDPE), and blends thereof. Other materials andconstructions can be used. The disclosed web material 100 can be rolledon a hollow tube, a solid core, or folded in a fan folded box, or inanother desired form for storage and shipment.

As shown in FIG. 1, the web material 100 can include a series oftransverse seals 118 disposed along the longitudinal extent of the webmaterial 100. Each transverse seal 118 extends from the longitudinaledge 112 towards an inflation channel 114. In the embodiment shown, theinflation channel 114 extends along the longitudinal edge 110 oppositethe longitudinal edge 112, and thus the transverse seal 118 extends fromthe longitudinal edge 112 toward the first longitudinal edge 110. Insome embodiments, the flexible structure 110 may include an inflationchannel 114 located elsewhere in relation to the longitudinal edge(s)112 and/or 110. For example, the inflation channel may extend along thelength of the structure 100 at an intermediate location (e.g., midway)between the longitudinal edge(s) 112 and/or 110. In some embodiments,the flexible structure 100 may, additionally or alternatively, includean inflation channel 114 along the longitudinal edge 112. In theillustrated embodiment, each transverse seal 118 has a first end 122proximate the second longitudinal edge 112 and a second end 124 spaced atransverse dimension d from the first longitudinal edge 110 of the film110. A chamber 120 is defined within a boundary formed by the seal orfold at longitudinal edge 112 and pair of adjacent transverse seals 118.

Each transverse seal 118 of the embodiment in FIG. 1 is substantiallystraight and extends substantially perpendicular to the secondlongitudinal edge 112. In other embodiments, other arrangements of thetransverse seals 118 may be used. For example, in some embodiments, thetransverse seals 118 may have undulating or zigzag patterns.

The transverse seals 118 as well as sealed longitudinal edges 110, 112can be formed by any of a variety of techniques known to those ofordinary skill in the art. Such techniques include, but are not limitedto, adhesion, friction, welding, fusion, heat sealing, laser sealing,and ultrasonic welding.

An inflation region, such as a closed passageway, which can be alongitudinal inflation channel 114, can be provided. The longitudinalinflation channel 114, as shown in FIG. 1, may be disposed between thesecond end 124 of the transverse seals 118 and the first longitudinaledge 110 of the film. Preferably, the longitudinal inflation channel 114extends longitudinally along the longitudinal side 110 and an inflationopening 116 is disposed on at least one end of the longitudinalinflation channel 114. The longitudinal inflation channel 114 has atransverse width D. In the preferred embodiment, the transverse width Dis substantially the same as the transverse dimension d between thelongitudinal edge 110 and second ends 124 of the transverse seals 118.It is appreciated, however, that in other configurations, a differenttransverse width D may be used.

The longitudinal edge 112 and transverse seals 118 cooperatively defineboundaries of inflatable chambers 120. As shown in FIG. 1, eachinflatable chamber 120 is in fluid communication with the longitudinalinflation channel 114 via a mouth (e.g. opening 125) opening towards thelongitudinal inflation channel 114, thus permitting inflation of theinflatable chambers 120 as further described herein.

In one embodiment, the flexible structure 100 may further include sealextensions 128 adjacent or connected to a respective transverse seal 118and extending toward or into the respective inflatable chamber(s) 120.The seal extensions 128 define perpendicularly lower regions of thechamber corresponding to smaller width or restrictions in the width ofthe chamber, which creates bendable areas, which can be aligned tocreate the bendable lines, thereby increasing the flexibility of webmaterial 100 such that it can be more easily bent or folded. Suchflexibility allows for the film 100 to wrap around regular and irregularshaped objects. The chamber portions 130 are in fluid communication withadjacent chamber portions 130 as well as with the inflation channel 114.The seal extensions can be any shape (e.g., rectangular as shown,circular, ovular, or having any other regular or irregular shape) orsize. In accordance with some embodiments, the transverse seals 118 arecontinuous, without interruptions from seal extensions or the like.

In some embodiments, the film 100 includes weakened portions 126 (e.g.,lines of weakness, such as perforation lines) disposed along thelongitudinal extent of the film 100 and extending transversely acrossthe first and second plies of the film 100. Each weakened portion 126extends from the second longitudinal edge 112 and towards the firstlongitudinal edge 110, e.g., partially or fully along the length of thetransverse seals 118. In the illustrated embodiment, the weekendportions 126 are in the form of transverse lines of weakness and eachtransverse line of weakness in the flexible structure 100 is disposedbetween a pair of adjacent chambers 120. For example, each line ofweakness 126 may be disposed between two adjacent transverse seals 118and between two adjacent chambers 120, as depicted in FIG. 1. Thetransverse lines of weakness 126 facilitate separation of adjacentinflatable cushions 121. In some embodiments, thicker transverse seals118 may be used, which define a transverse sealed portion and theweakened portions 126 may be provided along, at least part of thetransverse sealed portion of the flexible structure 100.

The weakened portions 126 may be provided in a variety of configurationsknown by those of ordinary skill in the art. For example, in someembodiments, the weakened portions 126 may be provided as transverselines of weakness 126 (e.g., as shown in FIG. 1) and may include rows ofperforations, in which a row of perforations includes alternating landsand slits spaced along the transverse extent of the row. The lands andslits can occur at regular or irregular intervals along the transverseextent of the row. The lands form small connections across the weakenedportion. Alternatively, for example, in some embodiments, the weakenedportions 126 may include score lines or the like formed in the flexiblestructure 100.

The transverse lines of weakness 126 can be formed by a variety oftechniques known to those of ordinary skill in the art. Such techniquesinclude, but are not limited to, cutting (e.g., techniques that use acutting or toothed element, such as a bar, blade, block, roller, wheel,or the like) and/or scoring (e.g., techniques that reduce the strengthor thickness of material in the first and second plies, such aselectromagnetic (e.g., laser) scoring and mechanical scoring).

Preferably, the transverse width 129 of the inflatable chamber 120 istypically less than 50 inches. Generally, the transverse width 129 is 3inches up to about 42 inches, more preferably about 6 inches up to about30 inches wide, and most preferably about 12 inches. The longitudinallength 127 between weakened portions 126 is typically less than 48inches. Generally the length 127 between weakened portions 126 is atleast about 2 inches up to about 30 inches, more preferably at leastabout 5 inches up to about 20 inches, and most preferably at least about6 inches up to about 10 inches. In addition, the inflated heights ofeach inflated chamber 120 can be at least about 1 inches up to about 3inches, and in some cases up to about 6 inches. It is appreciated thatother suitable dimensions can be used.

Turning now to FIGS. 2-6, an inflation and sealing device 102 forconverting the flexible structure 100 of uninflated material into aseries of inflated pillows or cushions 121 is provided. The uninflatedflexible structure 100 can be a bulk quantity of supply, uninflatedmaterial 134. For example, as shown in FIG. 2, the uninflated flexiblestructure 100 can be provided as a roll of supply material 134, whichmay be rolled around an inner support tube. In some embodiments, thesupply material may be rolled into a roll with a hollow center. Thesupport tube or hollow center of the roll of material 134 may besupported on a supply support element 136, in this case a roll axle 136,of the inflation and sealing device 102. The roll axle 136 accommodatesthe center or tube of the roll of web material 134. In otherembodiments, different structures can be used to support the roll ofmaterial, such as a tray, fixed spindle or multiple rollers, or a supplymaterial of different configuration (e.g., folded supply material).FIGS. 3-6 show the inflation and sealing device 102 without the flexiblestructure 100, such as the web material 134, loaded on the device. Insome embodiments, the flexible structure 100 of uninflated material isdelivered from a folded form such as a fanfolded configuration.

In accordance with various embodiments, the inflation and sealing device100 may include handling elements, with each of the handling elementsincluding film-supporting portions. The film-support portions maysupport and direct an inflatable web of material in a longitudinaldirection along a path (e.g., path E in FIG. 2). The handling elementsmay include a supply support element 136 that supports a supply 134 ofthe film 100 in an uninflated state. An inflation and sealing assembly132 may be operable to inflate the film with a fluid by directing thefluid between superimposed plies 105, 107 of the film 100 and to sealthe plies 105, 107 together to seal the fluid therein. Two of thefilm-supporting portions (e.g., a roll axle 136 and guide member 138)may be arranged relative to a supporting structure 141 and each othersuch that the supply material experiences a different amount of tensionalong the transverse direction as it passes from the first to the secondfilm-supporting portion. The relative position of the twofilm-supporting portions may cause a difference in tautness (or tension)in two portions of the web disposed transversely of each other in asubstantially same longitudinal location along the path. In furtherembodiments of the present disclosure, the differential tension may beachieved by providing the guide member 138 with one or more expansionelements as described further below. In some examples, the resultingshape of the guide member 138 may be configured to define a slightlyshorter longitudinal travel distance between the first and secondadjacent film-supporting portions at one transverse end of the film ascompared to the longitudinal travel distance between the first andsecond adjacent film-supporting portions at another (e.g., opposite)transverse location of the film, as will be further described.

Referring back to FIGS. 2-6, the inflation and sealing device 102 mayinclude a bulk material support 136. The bulk quantity of uninflatedmaterial may be supported by the bulk material support 136. For example,the bulk material support may be a tray operable to hold the uninflatedmaterial, which tray can be provided by a fixed surface or a pluralityof rollers for example. To hold a roll of material the tray may beconcave around the roll or the tray may convex with the roll suspendedover the tray. The bulk material support may include multiple rollers,which suspend the supply of web material. The bulk material support mayinclude a single roller that accommodates the center of the roll of webmaterial 134, e.g., as shown in FIG. 2. In this example, the bulksupport material may be a roll axle or spindle 136 passing through thecore or center of the roll of the material 134. Typically, the core ismade of cardboard or other suitable materials. The bulk material support136 may rotate about an axis Y.

The web material 100 is pulled by a drive mechanism 160. In someembodiments, intermediate members such as a guide member 138 (e.g.,which may include a fixed rod, or a roller) can be positioned betweenroll 134 and the drive mechanism 160. For example, the optional guidemember 138 can extend generally perpendicularly from a support structure141. The guide member 138 can be positioned to guide the flexiblestructure 100 away from the roll of material 134 and along a materialpath “B” along which the material is processed, also referred to aslongitudinal path. As shown in FIG. 2, the guide member 138 is arrangedbetween the material support 136, which supports the supply material,and the inflation and sealing components of the device 102. The guidemember 138 may be arranged to route the film 100 from the supply towardthe inflation and sealing assembly such that the film 100 follows acurved longitudinal path. The guide member 138 may include one or moresurfaces, which define film-supporting surfaces (e.g., surfacesextending along the side of the guide member around which the film bendsas it traverses the path B). In some examples, and as described furtherbelow, the guide member 138 may include one or more expansion elements.The one or more expansion elements provide at least a portion of thefilm-supporting surface of the guide member and can configure the guidemember to provide variable tension on the film 100 at differenttransverse locations of the film 100.

The guide member 138 or a portion thereof may be movably coupled to theinflation and sealing device 102, such that the guide member 138 or themovable portion thereof can move (e.g., spin, translate, oscillate,etc.) in relation to the support structure 141 when the film 100 isbeing drawn from the roll 134 by drive mechanism 160. In some examples,the guide member 138 may include a guide roller, which includes an axleor rod portion 137 and a rotatable or roller portion 139 coaxiallycoupled to the rod portion 137 such that the roller portion 139 spinsabout a common axis 148 of the rod and roller portions. The rollerportion 139 may provide a film-supporting surface 150 that supports thefilm 100, in this case moving with the film 100 as it is being drawnfrom the roll 134. The moving film-supporting surface 150 may reduce oreliminating sliding friction between the guide member 138 and the film100. However, guide members with a fixed film-supporting surface 150 arealso envisioned. For example, the guide member may include a rod similarto the axle 137 without the rotatable portion 139. A low frictionmaterial, such as polytetrafluoroethylene (PTFE), may be provided (e.g.,in the form of a coating or a strip of material adhered to) on at leasta portion of the film-supporting surface 150 of a non-rotatable rod, toreduce sliding friction. In yet other embodiments, the non-rotatableportion or rod of the guide member and the rotatable portion (e.g.,roller) may not be coextensive. For example, the only rotating portionof the guide member 138 may be the expansion element 152.Film-supporting surface(s) of the guide member which do not rotate asthe film is traveling over the guide member may be coated or otherwiseprovided with friction-reducing material(s).

In some embodiments, the guide member 138 may additionally oralternatively be coupled to the device 102 such that it moves in adirection normal to the longitudinal path B traveled by the supplymaterial, as indicated by arrow 139 in FIG. 3. Such movement may be usedto relieve an increase in tension experienced by the supply material asit travels along path E. For example, the guide member 138 may bespring-loaded or biased toward a first side 143 of the support structure141 in its nominal state (e.g., when unloaded or operating under normaltension of the supply material). An increase in tension experienced bythe film 100 along the portion between the supply end and the pinch zonetowards may be relieved by a downward movement of the guide member 138against the spring force. The spring constant may be selected to apply asufficient amount of biasing force against the film to maintain the filmtaut while being sufficiently soft to prevent the tension in the filmexceeding a threshold, which may damage the film and/or the device 102.A guide roller 138 movably coupled to the device 102 in this manner maybe interchangeably referred to as a dancer roller.

A guide member 138 according to the present disclosure may include oneor more expansion elements 152 as will be described further below. Insome embodiments, the expansion element 152 may provide some or all ofthe film-supporting surface 150 of the guide member 138. A guide member138 according to the principles of the present disclosure may thus beconfigured to control the material 134, such as to prevent or reducesagging of the film 100 between the roll 134 and the inflation nozzle140 of the device 102.

In various embodiments, the stock material (e.g. web material 100) mayadvance downstream from the stock roll of material (e.g., roll ofmaterial 134) without engaging a guide roll but may instead be advanceddirectly into an inflation and sealing assembly 132.

It is appreciated that other suitable structures may be utilized inaddition to or as an alternative to use of brakes, guide rollers, or webfeed mechanisms in order to guide the web material 100 toward a pincharea 176 which can form part of the sealing assembly 132. As indicated,because the web material 100 may sag, bunch up, drift along the guideroller 138, shift out of alignment with the pinch zone 176, alternatebetween tense and slack, or become subject to other variations indelivery, the inflation and sealing assembly 132 may need suitableadjustability to compensate for these variations. For example, a nozzle140 may be at least partially flexible, allowing the nozzle 140 to adaptto the direction the web material 100 approaches as the structure is fedtowards and over the nozzle 140, thereby making the nozzle 140 operableto compensate for or adapt to variations in the feed angle, direction,and other variations that the web material 100 encounters as it is fedtowards and over the nozzle 140. In some examples, as described above,the guide roller 138 may be transversely movable relative to the sealingassembly 132 such as to adjust or eliminate any variations in deliveryof the supply material.

The inflation and sealing device 102 includes an inflation and sealingassembly 132. Preferably, the inflation and sealing assembly 132 isconfigured for continuous inflation of the web material 100 as it isunraveled from the roll 134. The roll 134, preferably, comprises aplurality of chain of chambers 120 that are arranged in series. To beginmanufacturing the inflated pillows from the web material 100, theinflation opening 116 of the web material 100 is inserted around aninflation assembly, such as an inflation nozzle 140, and is advancedalong the material path “E”. In the embodiment shown in FIGS. 1-6,preferably, the web material 100 is advanced over the inflation nozzle140 with the chambers 120 extending transversely with respect to theinflation nozzle 140 and side outlets 146. The side outlets 146 maydirect fluid in a transverse direction with respect to a nozzle base 144into the chambers 120 to inflate the chambers 120 as the web material100 advanced along the material path “E” in a longitudinal direction.The inflated web material 100 is then sealed by the sealing assembly 103in the sealing area 174 to form a chain of inflated pillows or cushions121.

The side inflation area 168 (shown in FIG. 2) is shown as the portion ofthe inflation and sealing assembly along the path “E” adjacent the sideoutlets 146 in which air from the side outlets 146 can inflate thechambers 120. In some embodiments, the inflation area 168 is the areadisposed between the inflation tip 142 and pinch area 176. The webmaterial 100 is inserted around the inflation nozzle 140 at the nozzletip 142, which is disposed at the forward most end of the inflationnozzle 140. The inflation nozzle 140 inserts a fluid, such as pressuredair, into the uninflated web material 100 material through nozzleoutlets, inflating the material into inflated pillows or cushions 121.The inflation nozzle 140 can include a nozzle inflation channel thatfluidly connects a fluid source, which enters at a fluid inlet, with oneor more nozzle outlets (e.g. side outlet 146). It is appreciated that inother configurations, the fluid can be other suitable pressured gas,foam, or liquid. The nozzle may have an elongated portion, which mayinclude one or more of a nozzle base 144, a flexible portion, and/or atip 142. The elongated portion may guide the flexible structure to apinch area 176. At the same time the nozzle may inflate the flexiblestructure through one or more outlets. The one or more outlets may passfrom the inflation channel out of one or more of the nozzle base 144(e.g. outlet 146), the flexible portion 142 a, or the tip 142. Theinflation nozzle 140 may extend away from the front surface of thehousing.

As shown in FIG. 3-6, the side outlet 146 can extend longitudinallyalong the nozzle base 144 toward a longitudinal distance from theinflation tip 142. In various embodiments, the side outlet 146originates proximate, or in some configurations, overlapping, the sealerassembly such that the side outlet 146 continues to inflate theinflatable chambers 120 about right up to the time of sealing. This canmaximize the amount of fluid inserted into the inflatable chambers 120before sealing, and minimizes the amount of dead chambers, i.e.,chambers that do not have sufficient amount of air. Although, in otherembodiments, the slot outlet 146 can extend downstream past the entrypinch area 176 and portions of the fluid exerted out of the outlet 146is directed into the web material 100. As used herein, the termsupstream and downstream are used relative to the direction of travel ofthe web material 100. The beginning point of the web is upstream and itflows downstream as it is inflated, sealed, cooled and removed from theinflation and sealing device.

The length of the side outlet 146 may be a slot having a length thatextends a portion of the inflation nozzle 140 between the tip 142 andthe entry pinch area 176. In one example, the slot length may be lessthan half the distance from the tip 142 to the entry pinch area 176. Inanother example, the slot length may be greater than half the distancefrom the tip 142 to the pinch area 176. In another example, the slotlength may be about half of the distance from the tip 142 to the pincharea 176. The side outlet 146 can have a length that is at least about30% of the length of the inflation nozzle 140, for example, and in someembodiments at least about 50% of the length of the inflation nozzle140, or about 80% of the length of the inflation nozzle 140, althoughother relative sizes can be used. The side outlet 146 expels fluid outthe lateral side of the nozzle base 144 in a transverse direction withrespect to the inflation nozzle 140 through the mouth 125 of each of thechambers 120 to inflate the chambers 120. The tip of the inflationnozzle can be used to pry open and separate the plies in an inflationchannel at the tip as the material is forced over the tip. For example,when the web is pulled over traditional inflation nozzles, the tip ofthe traditional inflation nozzles forces the plies to separate from eachother. A longitudinal outlet may be provided in addition to or in theabsence of the lateral outlet, such as side outlet 146, which may bedownstream of the longitudinal outlet and along the longitudinal side ofthe nozzle wall of the nozzle base 144 of the inflation nozzle 140.

The flow rate of the fluid through the nozzle 140 form the blower 700 istypically about 2 to 20 cfm. But much higher flow rates can be used, forexample, when a higher flow rate fluid source is used, such as, theblower 700 can have a flow rate in excess of 100 cfm.

FIGS. 3, 6 and 7 illustrate a side views of the inflation and sealingassembly 132. As shown in FIG. 3, the fluid source can be disposedbehind a cover 184 or other structural support for the nozzle andsealing assemblies including a housing plate 185 on which the cover 184mounts. The cover 184 includes a sealing and inflation assembly opening184 a as shown in FIG. 3. The fluid source (e.g. from blower 700) isconnected to and feeds the fluid inflation nozzle conduit. The webmaterial 100 is fed over the inflation nozzle 140, which directs the webto the inflation and sealing assembly 132.

While various examples are described herein and shown in the FIGS. 2-7,it should be appreciated that these examples should not be limiting andthat the nozzle 140 and inflation assembly may be configured inaccordance with any known embodiments or developed embodiments that maybenefit from the disclosure herein as a person of ordinary skill in theart could apply based on the disclosure herein.

Preferably, the web material 100 is continuously advanced through thesealing assembly along the material path “E” and past the heatingassembly 400 at a pinch area 176 to form a continuous longitudinal seal170 along the web material 100 by sealing the first and second plies105,107 together. The longitudinal seal 170 is shown as the phantom linein FIG. 1. Preferably, the longitudinal seal 170 is disposed atransverse distance from the first longitudinal edge 102,106, and mostpreferably the longitudinal seal 170 is disposed along the mouths 125 ofeach of the chambers 120.

The web material 100 is advanced or driven through the inflation andsealing assembly 132 by a drive mechanism 160. The inflation and sealingassembly 132 may incorporate the drive mechanism or the two systems mayoperate independently. The drive mechanism 160 includes one or moredevices operable to motivate the flexible structure through the system.For example, the drive mechanism includes one or more motor drivenrollers operable to drive the flexible material 100 in a downstreamdirection along a material path “E”, such as those disclosed inUS2017/0282479. One or more of the rollers or drums are connected to thedrive motor such that the one or more rollers drive the system. Inaccordance with various embodiments, the drive mechanism 160 drives theweb material 100 without a belt contacting the flexible structure or insome embodiments, the entire system is beltless. In another example, thesystem has a belt that does not contact the web material 100 but insteaddrives the rollers. In another example, the system has a belt on somedrive elements but not others, such as those disclosed in US2015/0239196In other example, the system may have belts interwoven throughout therollers allowing the material to be driven through the system by thebelts. For example, U.S. Pat. No. 8,128,770 discloses a system thatutilizes belts and rollers to control the inflation and sealing ofcushions 121 and the disclosure provided herein may be utilized withsuch a system.

In accordance with various embodiments, the drive mechanism 160 includesopposing compression mechanisms 161 and 162. As illustrated in FIG. 6,the compression mechanism 161 is positioned adjacent to the compressionmechanism 162. The compression mechanism 161 is positioned relative tothe compression mechanism 162 such that the two compression mechanisms161, 162 together are operable to receiving the flexible material 100 ata pinch area 176. The pinch area 176 is defined by the area in which thecompression mechanism 161 and the compression mechanism 162 arepositioned against the web material 100 to pinch the web material 100there between. The pinch area 176 can extend from A to B shown in FIG.6.

The drive mechanism 160 can also include other compression mechanisms.The other compression mechanisms would also positioned adjacent to thecompression mechanism 162 or the compression mechanism 161. Therelationship between the other compression mechanisms and thecompression mechanism 162 or 161 can be such that the two compressionmechanisms form a second pinch area or extend the pinch area 176 inwhich the compression mechanisms contact and apply pressure to the webmaterial 100.

In accordance with various embodiments, the drive system forms a coolingzone 169 that is disposed contemporaneously with or downstream of thepinch area 176. In accordance with a particular example as shown in FIG.6, the pinch area 176 includes a heating zone 167 and a cooling zone169. The cooling zone 169 is defined at least partially betweencompression mechanism 162 and 161 within the pinch area 176. Thecompression mechanism 162 and/or the compression mechanism 161 forms apath from point A to point B of the pinch zone and at least a portion ofthis path allows for cooling the newly formed longitudinal seal 112 onthe flexible material 100 while still under pressure from thecompression mechanisms within the pinch area 176. The longitudinal seal112 is formed by a heating assembly 400 that is a part of sealingassembly 132.

The peripheral area the curved surface 162 a along the compressionmechanism 162 forms a contact area that engages the flexible materialdirectly. As discussed in more detail below, in some embodiments, theperipheral area is cylindrical and accordingly the peripheral area isthe outer circumferential area of the cylinder. In other embodiments,the peripheral area is the outer area of the surface of the shapedefining the compression mechanism 162. Absent the holding pressurecaused by the pinch area 176 against the cooling zone, the effectivenessof the longitudinal seal 112 would be reduced due to the air pressurewithin the inflated chamber. In accordance with various embodiments, thecooling zone is sufficiently long to allow sufficient cooling of thelongitudinal seal 112 to set in the seal such that the air pressurewithin the inflated chamber 120 does not stretch or deform thelongitudinal seal 112 beyond the longitudinal seal's 112 ability to holdthe air pressure therein. If the cooling zone is not sufficiently longsuch the longitudinal seal does not properly set.

The pinch area can have any suitable shape. For example, the pinch areamay be substantially rectilinear (e.g. 176′ in FIG. 9). In a preferredexample, the pinch area 176 is arcuate. Regardless of the shape, thepinch area can be made up of rollers, belts, or other suitable drivemechanisms. As shown in the FIGS. 2-7, the pinch zone is defined by acombination of belts and disks.

If the pinch zone is arcuate, and the angle between the pinch points Aand B is too large, the inflated material could wrap back on itself.Thus the location of the pinch point A and B relative to one anotheraround the curved surface path 162 a is preferably one that produces thebest seal without allowing the flexible material to interfere withitself thereby providing a superior with longitudinal seals 112 thatadequately hold the air. In accordance with various embodiments, thepinch point A is located at an angle that is greater than 15° from thepinch point B as measured around axis 161 a. In accordance with variousembodiments, the pinch point A is located at an angle that is less than180 from the pinch point B as measured around axis 161 a. In accordancewith various embodiments, the pinch point A is located at an angle thatis between than 85° and 145° from the pinch point B as measured aroundaxis 161 a. In accordance with various embodiments, the pinch point A islocated at an angle that is between than 105° and 125° from the pinchpoint B as measured around axis 161 a. In accordance with variousembodiments, the pinch point A is located at an angle that is about 115°from the pinch point B as measured around axis 161 a. In each of theabove embodiments and examples, it should be appreciated that the pinchpoints A and B are defined by the positions and/or shapes of thecompression mechanisms 161 and 162 relative to each other.

In accordance with various embodiments, the compression mechanisms caninclude adjustment mechanisms, biasing mechanisms or other suitabledevices for controller their relationship between one another or thepressures between one another.

In accordance with a preferred embodiment, the drive mechanism 160comprises opposing drive systems. In various examples, the opposingdrive systems form part of or all of the compression mechanisms 161 and162. In various examples, as illustrated in FIGS. 4-7, one portion ofthe drive mechanism can include a driven belt 163. In various examples,one portion of the drive mechanism can include a transport belt 164. Thetransport belt may be driven or alternatively may be a passive idlerfeature driven merely by the web material 100 or another driven featureof the system. One portion of the drive mechanism can include asecondary surface 310 corresponding to one belt surface. One portion ofthe drive mechanism can include a guide surface 410 corresponding toanother belt surface, roller surface, or stationary surface.

In accordance with various embodiments, the drive mechanism 160 includesthe compression mechanism 162. The compression mechanism 162 includesdriven belt 163. In some embodiments, belt 163 can define a portion ofthe web 134 path that is flat/rectilinear. In other embodiments, thebelt 163 defines a portion of the web 134 path that is arcuate. The belt163 pulls or pushes or otherwise transports the web 134 through thepinch area 176 and holds the web 134 sufficiently tight along the pathof the pinch area 176 (either flat or arcuate) to retain the fluidwithin the chamber 120 as the longitudinal seal 112 is applied and thencools. Holding the longitudinal seal 112 tightly closed in the coolingzone 169 via belt 163 limits the stretching and deformation against theseal 112 caused by the air pressure within the inflated chamber 120.

The drive mechanism 160 may drive the web 134 adjacent to the heatingassembly 400 such that the heat seal 112 is continuously created as theweb 134 is driven in a downstream direction. In one example, the drivemechanism 160 may tension the web 134 against the heating assembly 400,via one or more compression elements, to create the longitudinal seal112. More particularly, the belt 163 may be tensioned, as describedbelow, to create a compression force pinching at least a portion of theweb 134 against the heating assembly 400.

In accordance with various embodiments, the belt 163, which may bereferred to as an elastic belt, a first belt, or a second belt, includesmany configurations. For example, the belt 163 may include a compositionsuitable for transporting the web 134 through the pinch area 176. Thebelt 163 can have a high grip surface, such as a high tackiness and/orfriction material on a surface of the belt 163 (e.g., a tacky exteriorsurface). The high grip surface of the belt 163 may be defined as partof the belt 163 itself, such as integrally formed with the belt 163. Thehigh grip surface of the belt 163 may be resultant from the propertiesof the material from which the belt 163 is formed. In some examples, thehigh grip surface of the belt 163 may be achieved by application of asubstance or material onto the belt 163. For instance, a tacky substanceor material may be coated, sprayed, or otherwise applied to the belt163. In some examples, material may be coated, sprayed, or otherwiseapplied to the belt 163 to increase the friction between the belt 163and the web 134. In some examples, the high grip surface may be achievedby selective heating of at least a portion of the belt 163. For example,the belt 163 may be formed from a material such that heating of the beltincreases the tackiness and/or friction of the belt 163. As describedherein, a tacky material is one that is somewhat sticky, grippy, orgrabby such that the belt 163 grips the web 134 with a relatively smallforce against the web 134.

The belt can include an outer portion and an inner potion. The innerportion can include a reinforcement core, such as a Kevlar core. Thecore of the belt 163 may provide a desired structural characteristic.For example, the core may limit flexing or stretching of the belt,whether radially, longitudinally, or transversely, during operation. Thebelt 163 may be wider than the heating assembly 400. The belt 163 mayinclude a main surface, a bottom surface opposing the main surface, anda pair of opposing side surfaces extending between the main surface andthe bottom surface. The belt 163 may bias the web 134 towards theheating assembly 400. For example, the web 134 may be positioned betweenthe belt 163 and the heating assembly 400 such that the belt 163 pinchesat least a portion of the web 134 against the heating assembly 400. Inone example, the belt 163 may be positioned such that the main surfacepinches the web 134 against the heating assembly 400.

In one example, the outer portion of the belt 163 may facilitatetransporting the web 134 through the pinch area 176. For instance, theouter portion of the belt 163 may include a high grip characteristic.For instance, the belt 163 may include a high tackiness and/or a highfriction material on a surface thereof that contacts the web 134 to gripthe web 134 during heating by the heating assembly 400. Without the highgrip characteristic of the belt 163, the web 134 may move (e.g., slip orslide) relative to the belt 163 without the belt 163 being significantlytensioned against the web 134. The tackiness and/or frictioncharacteristic of the belt 163 may facilitate the belt 163 gripping orgrabbing the web 134 with less compressive force against the web 134. Assuch, the tension of the belt 163 needed to drive the web 134 in adownstream direction through the pinch area 176 may be significantlyreduced due to the high tackiness and/or friction characteristic of thebelt 163. In one example, the effective compression force of the belt163 through the pinch area 176 may be between a minimum of 15 lb., 20lb., or 25 lb. and a maximum of 30 lb., 35 lb., or 40 lb., such asbetween 25 lb. and 30 lb. In some designs not utilizing a high tackinessand/or a high friction belt, the effective compression force through thepinch area can be significantly higher, such as between two to fourtimes higher.

The high grip characteristic of the belt 163 may be defined by amaterial of the belt 163. For example, the belt 163 may be formed atleast partially from an elastomeric material. In one example, the tackyexterior surface is defined by an elastomeric material. In one example,the outer portion of the belt 163 may be formed at least partially froman elastomeric material. The elastomeric material may be a syntheticmaterial, a natural material, or a combination of synthetic and naturalmaterials. Depending on the particular application, the elastomericmaterial may be a saturated rubber, such as silicone, EPM, and/or EPDMrubber. The elastomeric material may be an unsaturated rubber, such asnatural, butyl, styrene-butadiene, and/or nitrile rubber. Theelastomeric material may be a thermoplastic elastomer, a thermoplasticpolyurethane, a thermoplastic olefin, and/or a thermoplasticvulcanizate. In one example, the belt 163 may be formed at leastpartially from a low durometer rubber or silicone. In some examples, thebelt 163 may be textured and/or shaped to include a high grip surface.For example, the belt 163 may include a high surface roughness. In someexamples, the belt 163 may be ribbed or otherwise configured to increasefriction between the belt 163 and the web 134.

In some examples, the belt 163 may be resiliently or elasticallystretchable. For example, the belt 163 may be formed at least partiallyfrom generally elastic material, such as rubber or silicone. In suchexamples, the belt 163 may stretch or elastically deform around adjacentstructure in driving the web 134 through the pinch area 176, asexplained below. The stretchable characteristic of the belt 163 may bein conjunction with or as an alternative to the high grip characteristicdescribed above. More particularly, the belt 163 may include a high gripcharacteristic, a stretchable characteristic, or a high grip andstretchable characteristic.

The belt 164 may be configured as described above, whether inconjunction with belt 163 or not. For example, the belt 164, which maybe referred to as a first belt or a second belt, may have a hightackiness characteristic, such as being formed from a high tackinessmaterial. In this manner, either the belt 163, the belt 164, or both thebelt 163 and the belt 164 may have a configuration suitable fortransporting the web 134 through the pinch area 176. As described morefully below, the web 134 may be positioned between the belt 163 and thebelt 164. In such examples, the drive mechanism 160 may include a hightackiness belt on either side of the web 134 to facilitate movement ofthe web 134 through the pinch area 176 with a lower effectivecompression force therethrough. In some examples, the belt 164 may beformed from a material different than the belt 163. For instance, thebelt 164 may be less tacky than the belt 163. In one example, the belt164 is formed at least partially from polytetrafluoroethylene, or othersimilar material.

In accordance with various embodiments, as illustrated in FIGS. 2-7,belts 163 and 164 oppose one another. Belts 163 and 164 are configuredrelative within the pinch area 176 and receive the web 134 therein. Morespecifically, in the embodiments shown, the belt 163 compresses againstthe web-support surface 410 defining the pinch zone, which overlapslongitudinally with the heating zone 167. In various embodiments, thepinch zone 176 includes a plurality of pressure regions transverse toone another. For example, the pinch zone 176 can include a first region276 a and a second region 276 b. In some embodiments, the plurality ofpressure regions can apply different forces on the web material 100. Inother embodiments, the pressure regions apply similar forces indifferent manners. In one example, a compression element (e.g. belt 163)presses against two different opposing pressure elements (e.g. disc 300and heater assembly 400). In this way the opposing pressure elements canapply pressure to the compression element in different ways creating twodifferent pressure regions (e.g. the first pressure region 276 a and thesecond pressure region 276 b). In instances of different pressure forcesin these regions the compression element (e.g. belt 163) can deflect ordeform to accommodate the different pressures. The deflection distanceD.P. can be from about 5 mils to 50 mils. The outer pressure can beconsidered an isolation pressure as it is able to aid in isolating thefluid in the air chambers 20. In embodiments where the forces aredifferent in each of the regions 276 a and 276 b, the differences can becaused for example, by a narrower region to pass the web materialthrough with respect to the other region. In another example, the regionsizes are similar but the opposing compression elements have differentmaterials. As such, the web material will deflect one material more andas a result one material will apply a higher pressure than the other. Inother embodiments, the different regions merely have pressure comingfrom different directions, or locations, or as illustrated in theexample of FIG. 7 the isolation element 300 actually extends into thecompression element (e.g. belt 163) whereas the support structure 405does not. In a preferred embodiment, the isolation element 300 is acontinuous surface that substantially matches the profile of the deviceforming the adjacent region. For example, the support surface 410 iscurved similarly to the isolation surface 410. In other embodiments, theisolation element 300 has a discontinuous surface 310. For example, theisolation element 300 can be a wheel that has fingers that contact themartial and sufficient intervals to limit fluid passage or otherwisestabilize the web material 100.

In accordance with various embodiments, the isolation element 300 isconfigured to block or resist the flow of fluid from the inflatablechambers 120 back toward the nozzle. Additionally or alternatively, theisolation element 300 is configured to isolate the portion of the webmaterial 100 that is being sealed from the movement of the portion ofthe web material 100 that extends transversely from the system. Eitherone or both of these results can be accomplished by an increasedpressure applied to the web martial transversely of the sealing region,or by applying a complex bend or curve to the web material 100 as itpasses through the sealing mechanism. In accordance with variousembodiments, the isolation element 300 can remain in contact with theweb material 100 through both the cooling and heating zones of thesealing mechanism. As discussed herein, the isolation element 300 and/orthe surface 310 is transversely offset from support structure 405 orother compression mechanism used to define the pinch zone. Preferably,the isolation element 300 and the support structure 405 arelongitudinally aligned. The transverse offset is sufficiently small toallow the isolation element 300 to bock or resist the flow of fluidbetween the chambers 120 and the nozzle. In one example, the offset G(see FIG. 7) is less than the thickness of the belt 163. In anotherexample, the offset is less than ½ the thickness of the isolationelements transverse thickness.

In accordance with one example as shown in FIG. 7, the compressionmechanism 161 includes an isolation element 300 having a surface, 164.For example, the belt 163 may bias the web 134 against the isolationsurface 310 of the isolation element 300. In such examples, the web 134may be biased against the secondary surface 310 to seal the fluid withinthe chamber 120 as the longitudinal seal 112 is created. As describedbelow, the isolation element 300 may deflect a portion of the belt 163in a direction generally normal to the main surface of the belt 163,such as upwardly or downwardly. In such examples, the belt 163 may flexto accommodate the deflection caused by the isolation element 300. Forinstance, the belt 163 may flex radially to accommodate the deflectionof the isolation element 300.

The isolation surface 310, which may be referred to as an isolationsurface or a second sealing surface or secondary surface, may beadjacent to the guide surface 410. In one example, the secondary surface310 can be generally aligned with the surface 410 in the longitudinaldirection L.D. In accordance with various embodiments, the isolationsurface 310 is located in front of, behind, or both in the transversedirection relative to the surface 410.

The secondary surface 310 may be stationary, flat or rectilinear,arcuate, or any combination thereof. In some embodiments, the isolationelement 300 may be rotating disc. Preferably, the belt 164 and theisolation surface 310 are offset longitudinally from one another.However, in alternative embodiments, they can overlap as well with thebelt 164 extending under the isolation surface 310. The isolationsurface 310 and the support surface 410 do not necessarily contact theopposing compression mechanism at the same level. Alternatively, theisolation surface 310 and the support surface 410 can have perpendicularoffsets relative to one another allowing on or the other to extendfarther into or towards the opposing compression mechanism (e.g. belt163). As used herein the perpendicular direction of the offset is thedirection perpendicular to the major surface of the web material as itmoves through the system. Even when accounting for intermediatecomponents (e.g. belt 164, heating element 450, low frictionintermediary 460, etc., discussed in more detail below), the isolationsurface 310 can extend farther into or towards the belt 163 than surface410 with the intermediate components defining a disk pressure offsetD.P. FIG. 7 illustrates the disk pressure offset D.P. The disk pressureoffset D.P. is about 0.020 inches. In some embodiments, the surface 310is stationary. In some examples, the surface offset D.P. may be equal tothe material thickness of the web 134, greater than the materialthickness of the web 134, or less than the material thickness of the web134. In these and other examples, the belt 163 may flex radially toaccommodate the surface offset D.P. between the surfaces 310 and 410. Inembodiments where the belt 163 is resiliently or elasticallystretchable, the belt 163 may resiliently or elastically stretch toconform to the surfaces 310 and 410. For instance, the belt 163 maydeform elastically around the surfaces 310 and 410 to accommodate thesurface offset D.P. between the surfaces 310, 410. In such examples, thebelt 163 may resiliently stretch in a direction normal to the mainsurface of the belt 163 to accommodate the surface offset D.P.

The belt 163 may create respective compression forces pinching at leastportions of the web 134 against the surfaces 310 and 410. In suchexamples, the compression forces of the belt 163 at the surfaces 310 and410 may be different. For instance, the compression force of the belt163 against the surface 410 may be lower than the compression force ofthe belt 163 against the surface 310. In such examples, the surfaceoffset D.P. may create the different compression forces of the belt 163against the surfaces 310 and 410. The compression forces may besufficient to achieve a desired functional characteristic. For example,the compression forces may be low but sufficient to permit the belt 163to drive the web 134 through the pinch area 176. Additionally, thecompression force of the belt 163 against the surface 310 may besufficient to limit air leakage from the chamber 120 while the seal 112is created adjacent to surface 410. More particularly, the compressionforce of the belt 163 against the surface 310 may be sufficient tosubstantially isolate the pressure inside the chamber 120 from the heatseal area adjacent to surface 410.

In other embodiments, the surface 310 forms a part of a rotating disc300. In such embodiments, as the web material moves through the sealingassembly, the web material rotates the disc. In other embodiments, thedrive system rotates the disc.

FIGS. 9A and 9B illustrate an alternate embodiment having a flat pinchzone 176′, in the embodiment upper (164 a/b) and lower (e.g. 163 a/b)compression element apply pressure to the web material 100 at differentlevels deflecting the material laterally. For example, belts 163 a and163 b are offset in in the perpendicular direction relative to oneanother a distance of D.P.′. The pressures are offset relative to oneanother a distance of D.P due to the different opposing compressionelements applying pressure at different levels. In this way a linearpinch zone 176′ also establishes different pressure regions 276 a′ andregions 276 b′. Internal structures such and support 163 c and/orheating assembly 400′ can also be position or biased to provide orresist pressure from the other elements.

FIGS. 9C and 9D illustrate an alternate embodiment having a flat pinchzone 176″, in the embodiment the upper (164 a/b″) and the lower single(e.g. 163 d″) compression element apply pressure to the web material 100at different levels deflecting the material laterally and the lowercompression element laterally. The opposing compression elements 164 a″or 164 b″ with 163 d″ form the opposing pressure causing the offset D.P.In this way a linear pinch zone 176″ also establishes different pressureregions 276 a″ and regions 276 b″. This is shown as an example with asingle lower belt that is also deflected D.P. The deflection can helpisolate fluid out of the nozzle and away from the forming seal.

In accordance with various embodiments, the drive mechanism 160 includesthe compression mechanism 161. The compression mechanism 161 can includebelt 164. In accordance with various embodiments, the compressionmechanism 161 includes guide surface 410. In accordance with variousembodiments, the guide surface 410, which may be adjacent to the heatingassembly 400 and which may be referred to as a first sealing surface,may set at least a portion of the belt path of the belt 163 and/or thebelt 164. For example, the belt 163 and/or the belt 164 may wrap aroundthe guide surface 410. In some examples, the guide surface 410 mayprotrude into a line between adjacent belt supports to form a bent beltpath. In some embodiments, the guide surface may be movable, e.g. beingthe surface around an idler or drive pulley. As illustrated in FIGS.7-8, the guide surface 410 is stationary. As seen from a side view ofthe drive mechanism (i.e. transversely across the web), the guidesurface can be flat/rectilinear (see e.g. FIGS. 9A and 9B) or the guidesurface can be arcuate (see e.g. FIG. 6). In one example, as illustratedin FIGS. 8A-8E the guide surface is arcuate and sets at least a portionof the path of the drive mechanism (e.g. belt 164) in an arc as shown byexample in FIG. 6. Additionally or alternatively, the drive mechanism(e.g. belts 163 and 164) forms a part of the compression mechanism andpulls against or otherwise places a compressive pressure against anopposing surface (e.g. the web-support surface 410), where one or moreof the compression mechanisms are sufficiently stationary to provide anopposing force. In this manner the opposing surface (e.g. web supportsurface 410) defines a portion of the path for both belts 163 and 164.This portion of the path is the pinch area 176. In such examples, belts163 and 164 may be biased against the guide surface 410 to pinch theplies of web 134 together. In a preferred embodiment, the guide surface410 is at least partially circular and/or circular through the pinchzone 176.

To elaborate on the particular example shown in FIGS. 2-7, the drivemechanism 160 can include a compression belt 163 and a transport belt164. The compression belt 163 wraps around a drive pulley (e.g. 171) andone or more idler pulleys (e.g. 173). Any of the pulleys can include atensioning mechanism for locating or tensioning the compression belt163. The drive mechanism 160 may also include an idler pulley (e.g. 175)position to wrap the compression belt around an opposing compressionelement. As shown in this example the opposing compression element isthe heating assembly 400. The heating assembly 400 includes the supportstructure 405 which defines the support surface 410. The pulleys arepositioned to cause the compression belt 163 to wrap around and exert apressure on the support surface 410. This interaction defines the pinchzone 176. The drive mechanism can also include a transport belt 164which is also wrapped around the support surface 410. Pulleys 177 cansupport, guide, and position the transport belt around the supportsurface 410. Any of the pulleys can include a tensioning mechanism forlocating or tensioning the transport belt 164.

In accordance with various embodiments, the transport belt can be a lowfriction material especially in comparison to the compression belt 163.In a preferred embodiment, the transport belt 164 is a Teflon belt. In apreferred embodiment, the transport belt is about 5-50 mils thick.

Of note, and to reiterate the description above, the drive mechanism canbe any suitable system including belts, rollers, or other suitabletransportation devices. The embodiments illustrated in FIGS. 2-7 anddescribed herein, are merely examples of one type of suitable system,the system using opposing belts that and a pressure disc. A person ofordinary skill in the art will understand in light of the disclosureherein that the concepts discussed with respect to the belts or thedisks may be applied to other systems utilizing rollers or other webtransportation devices.

In accordance with various embodiments, the inflation and sealing device102 may include one or more covers (e.g. 182 and 184) over the inflationand sealing assembly 132. The covers (e.g. 182 and 184) can be operableto redirect the web after the web exits the pinch area 176 at point B.For example, the covers include a deflection surfaces 182 a and/or 184 athat contacts the flexible material 100 as it exists at point B and aidsin separating the flexible material 100 from the compression mechanisms161 and 162 redirecting the web material 100 in any desired direction.The cover may be a harder material than the rollers and sufficientlysmooth and continuous to have relatively little engagement or adheringtendency with the web material 100.

In each of these various systems for drive mechanisms referred to above,the sealing assembly 132 also includes a heating assembly 400 operableto seal the different layers of the web material 100 to one another.

In accordance with a preferred embodiment, the heating assembly 400 isstationary. Examples of various heating assemblies and heating elementspositioned stationary while the flexible material 100 and the drivemechanisms move relative to the heating assemblies and heating elementsare depicted in FIGS. 8A-8E. By positioning the heating assembly 400 sothat the heating assembly 400 remains stationary while the flexible webmaterial 100 moves across the heating assembly 400, the entire seal isformed by the same section of heating assembly allowing for greaterconsistency in heating assembly temperature, positioning, and overallconditions, which in turn provides for consistent seals. The stationaryposition of the heating assembly 400 also allows for simplifiedconstruction of certain heating elements and or heating elementtensioning mechanisms, which further improves the consistent applicationof the seals.

In accordance with various embodiments, the heating assembly 400 candefine at least a portion of the path E. In more particular embodiments,the heating assembly 400 can define a portion the pinch zone 176 alongpath E. As discussed above, this portion of the path E can berectilinear or curved. FIG. 9 illustrates an example of a rectilinearpath. Whereas the FIGS. 2-8 illustrate an example of a curvilinear path.In either embodiment, the heating assembly 400 can support the heatingelement 450. This may be done directly or indirectly. For example, abelt mounted over the heating assembly 400 may be used to direct heat tothe web-material 100. In other examples, a separate heating element 450may be mounted directly to the heating support structure 405. In such anexample, other covers shield, belts, or suitable protective devices canseparate the heating element 450 from the web-material 100. For example,protection element 460 can cover the heating element 450 protecting itfrom the transport belt or other moving feature of the system (e.g.film, compression element, roller, etc.).

In one example, the heating assembly 400 is attached to or otherwiseextends from the cover 185. As discussed above, the heating assembly 400is positioned adjacent to one or more drive members and relative to thecompression mechanism 162 or 163. In a more particular example, theheating assembly, when viewed from the side as shown in FIG. 7B, theheating assembly is mounted and defines surface 410 that sets at least aportion of the curvature of belts 163 and 164. In accordance withvarious embodiments, the heating assembly 400 includes a firstconductive support 402, a second conductive support 404, an insulativesupport 406, and a heating element 450. The first conductive support402, second conductive support 404, insulative support 406 are connectedtogether and define the web-support surface 410. In various examples,the heating element 450 is oriented along surface 410. Preferably, theheating element is longitudinally straight with both narrow and widepotions receiving pressure in the pinch zone 176.

In accordance with various embodiments, the heating element 450 iselectrically connected to both conductive supports 402/404. The heatingelement is laid across and supported by the conductive and insulativesupport 406. The portion of the heating element 450 that is laid acrossand supported by the conductive and insulative support 406 defines, atleast in part, a portion or all of the heating zone 167. In thisembodiment, the insulative support 406 electrically separates theconductive supports 402/404. Alternatively or additionally theinsulative support 406 can be thermally insulating. With thermallyinsulating properties, the insulative support 406 can help control thetemperature differential between the cooling zones and the heatingzones, thereby improving the seal quality and/or efficiency.

In accordance with various embodiments discussed herein, the heatingelement 450 may include a high heat region 454 that has relatively hightemperature compared to the remaining extent of the heating element 450.The heat zone 454 of heating element 450 corresponds to the heating zone167. The high heat region 454 is offset to the upstream end of thesurface 410. The upstream end of the web-support surface 410 alsocorresponds to the upstream end of the pinch zone 176. By offsetting theheating zone 167 to the upstream end of the pinch zone 176, the pinchzone 176 can be utilized to apply pressure to the web material 100during both the heating portion of the process and the initial coolingprocess. In some embodiments, the heating element 450 can have differentsections of different heat levels that extend throughout various regionsalong the material path of the pinch zone 176. In this way, thetemperature of the web material 100 can be controlled after the seal isformed in the heating zone 167, while still applying pressure via thepinch zone 176.

In accordance with various embodiments, the heating element 450 extendsthe entire length of the pinch zone 176. Preferably, the heating element450 is longer than the pinch zone 176 but in some examples can beshorter. Within the pinch zone 176 there is a heating zone 167 and acooling zone 169 after the heating zone. In various examples, the heatzone is between about ¼ and ½ the length of the heating element.Preferably the heat zone is about ¼ the length of the heating element.In various examples, heat zone is between about ½ and ¾ the length ofthe pinch zone. Preferably, the heat zone is about ⅔ the length of thepinch zone. The cooling zone is between about ¼ and ½ the length of thepinch zone. Preferably, the cooling zone is about ⅓ the length of thepinch zone 176.

In various embodiments, the heating assembly 400 is positionedtransversely between the nozzle 140 and the chambers 120 being inflatedto seal across each of the transverse seals. Some embodiment can have acentral inflation channel, in which case a second sealing assembly andinflation outlet may be provided on the opposite side of the nozzle.Other known placement of the web and lateral positioning of theinflation nozzle and sealing assembly can also be used.

After inflation, the web material 100 is advanced along the materialpath “E” towards the pinch area 176 where it enters the sealing assembly103. In one example, the pinch area 176 is disposed between adjacentcompression mechanisms 161 and 162. The pinch area 176 is the region inwhich the first and second plies 105,107 are pressed together or pinchedto prevent fluid from escaping the chambers 120 and to facilitatesealing by the heating assembly 400. As illustrated in FIG. 5, the pincharea 176 may include a pinch region between the compression mechanism162 and the heating assembly 400. The pressure produced in this pincharea between compression mechanism 162 and the heating assembly 400helps form the seal. As indicated above, the heating assembly 400 can bestationary. Thus, in such embodiments, the pinch area 176 between thecompression mechanism 162 and the heating assembly 400 includes a movingelement, e.g. the compression mechanism 162 and a substantiallystationary element, e.g. heating assembly 400. In accordance withvarious embodiments, the drive mechanism 160 rollers 161 and 162 can becompressed against one another for driving the flexible material 100through the system and the rollers 161 and 162 can open for threadingthe flexible material 100 over the drive mechanism 160. Similarly, theopen state of the drive mechanism 160 also allows threading the flexiblematerial 100 between the heating sealing assembly 400 and the opposingroller 162 as shown in FIG. 5.

The heating assembly 400 includes a heating element 450 disposedadjacent to the pinch location to heat the pinch area 176. While in thevarious embodiments disclosed herein the compression mechanisms adjacentto the pinch area 176 can roll, the heating element assembly 400 is astationary heating element. As indicated above, the pinch area 176 isthe area where the compression mechanisms 161 and 162 are in contactwith each other or with the web material 100 and similarly compressionmechanism 162 and heating element assembly 400 are in contact with eachother or with the flexible material 100.

As discussed above, the heating assembly 400 includes one or moreheating elements 450. The heating elements can be any material or designsuitable to seal together adjacent plies together. In variousembodiments the heating elements 450 can be resistive wire or foil. Thewire or foil can be formed of nichrome, iron-chromium-aluminium,cupronickel or other metals suitable for forming and operating a heatingelement under conditions that are used for sealing plies of the flexiblematerial together allowing the heating element 450 to melt, fuse, join,bind, or unite together the two plies 105,107. In a preferredembodiment, the heating element 450 is formed from about 80% nickel and20% chromium annealed soft. In other embodiments, the heating element450 can be a thin film heater element. The thin film heating element 450can be formed of barium titanate and lead titanate composites or othermaterials suitable for forming and operating the heating element underconditions that allow the heating element 450 to obtain a sufficientheat to seal the plies together. In accordance with various embodiments,the heating element 450 heats up to between about 300° to 500° F.Preferably the heating element 450 reaches about 400° F. The ends of theheating element reach a lower heat of between about 125° to 225° F.Preferably the ends reach about 180° F.

In accordance with various embodiments, as illustrated in FIG. 8F, theheating element includes a high heat portion 454 and a low heat portion459. The high heat portion 454 is defined by a portion of the heatingelement's 450 length with a reduced cross-section. The reducedcross-section increases the resistance in the heating element. Theincreased resistance causes the heating element 450 to significantlyincrease in temperature across the high heat portion 454 that issufficient to heat the plies to create the longitudinal seal that sealsthe first and second plies of film together. The low heat potion 459 isdefined by regions of the heating element that have a largercross-section than the low heat portion. The larger cross-sections havea lower resistance in response to an applied current resulting in alower temperature of the low heat portion 459. In various embodiments,the low heat portion is significantly above ambient temperature of thesealing device. In various embodiments, the high heat portion 454 islocated closer to one end of the heating element 450 than the other endof the heating element 450. This offset position allows the high heatportion 454 to be offset on the upstream end of the pinch zone discussedabove.

In accordance with an example of the heating element 450, the heatingelement 450 is about 7 to 7½ inches. The heating element 450 includes afirst low heat portion 459 having a length L3 of between 3¼ to 3¾. Theheating element 450 includes a second low heat portion 459 having alength L1 of between about 1¾ to 2¼. The low heat portions are about ¼to ⅜ inches wide. The low heat portions are connected at a high heatportion 454 with a length L2 of between about 1½ and 2 inches. Theelement is about ⅛ of an inch wide. The heating element 450 may be from1-5 mils thick and preferably about 3 mils thick. In response to acurrent being applied across the heating element 450, the low heatportion heats up to about 180° F. and the high heat portion heats up toabout 400° F.

In accordance with various embodiments, as illustrated in FIG. 8F, theheating element includes connection elements 453 and 455 one each endsuitable to attach to the heating assembly 400. In one example theconnection elements are apertures operable to be connected to connectionelements 415/416 on the heating support structure 405.

In accordance with various embodiments, a low friction layer 460 islocated between the stationary heating element 450 and the moving roller162 or flexible material 100. The low friction layer 460 is suitable todecrease the wear between the roller 162 and the heating element 450. Inembodiments having a heating element 450, the low friction layer 460decreases abrasion to the element and may also limit the tendency of theheating element 450 to cut into the flexible material 100 duringsealing. In embodiments having a thin film heat element 450, the lowfriction layer 460 decreases abrasion to the substrate supporting theheating element 450 and the heating element 450 itself. As the thin filmheat element 450 tends to be structurally thinner than wire heatingelements, the low friction layer 460 also limits the deterioration ofthe thin film heating element 450 due to abrasion. The low frictionlayer 460 also allows for smoother transition of the flexible material100 across the heating element 450 improving the seal. In one example,the low friction layer is a thin strip of polytetrafluoroethylene (PTFE)attached across the exposed portion of the heating element 450.Additionally by using the PTFE as a wear element, the layer can bereplaced without replacing the more expensive heater element. The PTFEcan be attached as a tape to the heating element and surroundingcomponents. A non-adhesive layer of PTFE can also be mechanicallypositioned relative to the heating element. Mechanical fixturing allowsthe swapping out of parts without concern over the adhesive. Forexample, screw attachments or clips or other mechanical hardware to holdthe PTFE in place or a housing can be molded to accommodate the layer.In other examples, other low fiction materials that can accommodate theheat created at the heating element 450 such as silicone are applied.

In accordance with one embodiment as illustrated in FIGS. 8A-8E, theheating element 450 is a NiChrome wire or foil. The heating element 450includes the NiChrome wire 450 stretched across an insulator block 406.Each side of the NiChrome wire 450 is attached to contacts 415 and 416.Electrical leads 451 and 452 are connected to the contacts 415 and 416such that current can be provided to the heating element 450 to cause itto heat up. By controlling the width of the wire the heat output isaffected. For example, narrowing the wire width increases the heatoutput compared to the same electrical input. This has the drawbackhowever of narrowing the seal formed on the flexible material. In someexamples, the seal width is controlled by providing multiple traces ofwire for the heating element.

In accordance with one embodiment as illustrated in FIGS. 8A-8E, theheating element 450 is a thin film heater. In such embodiments, theheating element assembly 410 includes a heating element 450 having athin film heat trace that connects two contacts. The heating element 450can be suspended by a substrate. For example, the heating elementassembly includes a polyimide substrate that backs the heat trace. Theheating element 450 can be sandwiched between two layers of substrate.The heating element 410 can formed by vapor deposition on a polyimidelayer. In one example, the polyimide layers are between about 1 and 3mils thick. In a preferred example, the polyimide layers are about 2mils thick each. The polyimide layers sandwich the heat trace 450, whichin one example is between about 1 and 3 mils thick. In a preferredexample, the heat trace 450 is about 2 mils thick. The polyimide layersencapsulate the heat trace and provide isolative properties. The processthat binds the polyimide together handles the temperature that theheating element 450 is capable of creating, eliminating the need foradhesives. Typically the adhesives have a lower functional temperatureand as such are generally avoided with heating elements. In addition onevariable is eliminated from the assembly by bonding the polyimidedirectly to itself.

In other embodiments the heating element 450 circuit can be formed oflayers of fluorinated ethylene propylene (FEP) on the heat trace 450. Inthis structure high heat and high pressure negates a need to use anadhesive. Also the outer layer of FEP can be textured to decreasefriction and sticking with other components. In other embodiments, thethin film circuit 410 can be subsequently wrapped in another materialsuch as silicone providing additional protection, provides insulation,acts as a bonding agent and provides additional manufacturing optionssuch as over-molding of the circuit.

The heating element 450 is held in tension across a backing block 406.Each of the two contacts on the heating assembly 400 is connected toheating assembly contacts 415 and 416, which in turn are connected toelectrical leads 451 and 452. In any of the heating assembly embodimentsdiscussed herein, the heating element 410, contacts 415/416, and theinsulator block may be positioned inside or outside of the structure ofheating assembly 400. The low friction layer 460 may also be appliedalong the surface 410.

In various example, the housing of heating assembly 400 has an elongated“U” shape suitably sized to the belt path and web path through the pinchzone 176 alone surface 410 of the “U” shaped housing while the housingremains stationary. The housing can also include standoffs 472 and 474suitable to align the housing 420 with the belts 163 and/or 164. In oneexample, the standoffs attach to the plate 185 and space the housingaway from the plate the proper distance to align the housing belts. Thestandoffs 472 and 474 also can house the electrical leads respectively.While it is discussed herein by way of example, that the heatingassembly 400 aligns with a belt drive mechanism, it should beappreciated that other embodiments are also covered, such as alignmentwith the end of a roller or drum, or alignment with a belt drivemechanism, or any structural relationship that allows the flexiblematerial to be conveyed past the stationary heating assembly. In anotherembodiment, the flexible material could be stationary and the heatingassembly driven across the stationary flexible material.

In accordance with various embodiments, the heat sealer assembly 400includes a tension mechanism for the heating element 410. The tensioningmechanism is a system configured to hold tension in the heating element410 across the backing block 406. As the heating element heats up andcools down, the length and/or structure of the heating element changes.These changes can modify the relationship between the heating element410 and the surrounding components or the flexible material 100. In wireapplications, the change in length of the wire heating element can besufficiently large causing poor seals to form and potentially causingthe wire heating element to cut the flexible material 100. As theheating element due to increase in temperature the added length of theheating element is “absorbed” by the tension mechanism allowing theheating element to remain flush against the backing block and stay inposition. When the heating element is not flush against the backingblock, there is the potential of cutting the film as you seal. Constantpressure will provide a consistent seal. In various embodiments, one ormore of the contacts 415 and 416 can be resilient thus providing a forceto stretch the heating element across the backing block 406. In oneexample, shown in FIG. 8C, the contact block 402 includes a lever andspring, placing the heating element 450 in tension. The spring 482 issuspended on a shelf in the housing of block 402 allowing the lever 480to pivot away from the spring 482 placing the heating element 450 intension. The spring tensioning mechanism also allows for changes intension in the heating element during thermal expansion.

In another example, as shown in FIG. 8C, the tension mechanism can bebuilt into the heating element assembly 400. The thickness of the heattrace or physical pattern can be modified to provide various wattdensities. The thin film element can have varying widths and lengths bychanging the trace composition. The thin film element is also smootherdecreasing or eliminating the likelihood of cutting the flexiblematerial 100 with the heating element.

While the various embodiments and examples discussed herein are directedto a heating assembly 400 that is stationary, it should be appreciatedthat various features or elements of the various embodiments andexamples discussed herein are applicable to some moving heatingassemblies as well. In one example, the heating assembly 400 includesthe disk 300. Thus, some of the heating element assembly structurescould move with the drive mechanism while others remain stationary. Inanother example, some of the heating element tensioning mechanisms couldapply to moving heating assemblies. In other embodiments, the heatingelement assembly may move with the drive elements, be stationaryrelative to the moving drive elements, move relative to the movement ofthe compression mechanisms, move relative to the web material 100, or bestationary relative to the housing 141. Persons of ordinary skill in theart, based on the disclosure herein, can adapt these features andelements to a variety of other systems only some of which are disclosedherein in detail.

After being sealed, the first and second plies 105,107 are cooled underpressure along the cooling zone 169 allowing the seal to harden. Thecooling zone 169 may act a heat sink or may provide a sufficient coolingtime for the heat to dissipate into the air.

In the preferred embodiment, the heating assembly 400 and one or more ofthe compression mechanisms 161, 162 cooperatively press or pinch thefirst and second plies 105,107 at the first pinch area 176 against theheating assembly 400 to seal the two plies together. The sealingassembly 103 may rely on pressure from compression mechanism 162 againstthe heating assembly 400 to sufficiently press or pinch the plies105,107 there-between.

In accordance with various embodiments, the inflation and sealingassembly 132 may further include a cutting assembly 250 to cut the webmaterial 100. Preferably, the cutting member is sufficient to cut theweb material 100 as it is moved past the edge along the material path“E”. More particularly, the cutting assembly 250 may cut the first andsecond plies 105, 107 between the first longitudinal edge 101 and mouth125 of the chambers. In some configurations, the cutting assembly 250may cut the web material 100 to open the inflation channel 114 of theweb material 100 and remove the first and second plies 105, 107 from theinflation nozzle 140. In various embodiments, the inflation channel 114of the flexible structure can be central to the structure or in otherlocations. In such embodiments, the cutting assembly 250 can still beadapted to remove the inflation channel 114 from the inflation andsealing assembly, particularly the nozzle 140.

Any and all references specifically identified in the specification ofthe present application are expressly incorporated herein in theirentirety by reference thereto. The term “about,” as used herein, shouldgenerally be understood to refer to both the corresponding number and arange of numbers. Moreover, all numerical ranges herein should beunderstood to include each whole integer within the range.

Having described several embodiments herein, it will be recognized bythose skilled in the art that various modifications, alternativeconstructions, and equivalents may be used. The various examples andembodiments may be employed separately or they may be mixed and matchedin combination to form any iteration of the alternatives. Additionally,a number of well-known processes and elements have not been described inorder to avoid unnecessarily obscuring the focus of the presentdisclosure. Accordingly, the above description should not be taken aslimiting the scope of the invention. Those skilled in the art willappreciate that the presently disclosed embodiments teach by way ofexample and not by limitation. Therefore, the matter contained in theabove description or shown in the accompanying drawings should beinterpreted as illustrative and not in a limiting sense. The followingclaims are intended to cover all generic and specific features describedherein, as well as all statements of the scope of the present method andsystem, which, as a matter of language, might be said to fall therebetween.

1. A protective packaging formation device, comprising: an inflationassembly that directs fluid between first and second overlapping pliesof a web material; a sealing mechanism that includes an arcuateweb-support surface, which web-support surface includes: a heater thatdefines a heating zone that is operable to heat the plies to create alongitudinal heat seal that seals the first and second plies together asthe web is driven over the heating zone in a downstream direction, and acooling zone disposed downstream of the heating zone operable to allowthe heated plies to cool at the longitudinal heat seal as the web isdriven over the heating zone in a downstream direction, such that thecooled longitudinal heat seal retains the fluid between the plies; and adriving mechanism that drives the film in the downstream direction overthe heating and cooling zones, with the web supported by the web-supportsurface from an upstream location to a downstream location; wherein theheating zone of the web-support surface is disposed offset towards theupstream location.
 2. The protective packaging formation device of claimof claim 1, wherein the inflation assembly has a nozzle insertablebetween the plies to direct the fluid between the plies, wherein thedriving mechanism directs the web over the nozzle in the downstreamdirection
 3. The protective packaging formation device of claim of claim1, wherein the heating and cooling zone has an arcuate profile.
 4. Theprotective packaging formation device of claim of claim 3, wherein thearcuate profile is convex.
 5. The protective packaging formation deviceof claim of claim 4, wherein the driving mechanism comprises a belt thatholds the web against the arcuate profile defining a pinch zone.
 6. Theprotective packaging formation device of claim 5, wherein the heat zoneis between 25 and 75% of the pinch zone longitudinal length.
 7. Theprotective packaging formation device of claim 5, wherein the coolingzone is between 25 and 75% of the pinch zone.
 8. The protectivepackaging formation device of claim 5, wherein the heater is a thin filmheater that follows the web-support surface.
 9. The protective packagingformation device of claim 8, wherein the sealing mechanism includes aheater support having two electrically conductive supports and anelectrically insulative support between the conductive supports, theconductive and insulative supports cooperatively forming the web-supportsurface for the web with the thin film heater extending from oneelectrically conductive support to the other.
 10. The protectivepackaging formation device of claim 8, wherein the insulative supportextends for more than half of the pinch zone and the heat zone is centeron and extends for more than half of the web-support surface that isdefined by the insulative support.
 11. A protective packaging formationdevice, comprising: an inflation assembly that directs fluid betweenfirst and second overlapping plies of a web material; a sealingmechanism that includes: a heater support having two electricallyconductive supports and an electrically insulative support between theconductive supports, the conductive and insulative supportscooperatively forming a support surface for the web; a heating zonedefined by a first portion of the support surface and operable to heatthe plies to create a longitudinal heat seal that seals the first andsecond plies together as the web is driven over the heating zone in adownstream direction, and a cooling zone disposed downstream of theheating zone along a second portion of the support surface and operableto allow the heated plies to cool at the longitudinal heat seal as theweb is driven over the heating zone in a downstream direction, such thatthe cooled longitudinal heat seal retains the fluid between the plies;and a driving mechanism that drives the film in the downstream directionover the heating and cooling zones, with the web supported by theweb-support surface from an upstream location to a downstream location.12. The protective packaging formation device of claim of claim 11,further comprising a heating element electrically connected to bothconductive supports such that the heating element is supported by theconductive and insulative supports, wherein the heating element includesa heating zone disposed over and supported by the insulative support.13. The protective packaging formation device of claim of claim 11,wherein the support surface is arcuate.
 14. The protective packagingformation device of claim of claim 11, wherein the support surface issubstantially continuous from an upstream one of the conductive supportsover the insulative support and over a downstream one of the conductivesupports.
 15. The protective packaging formation device of claim ofclaim 11, wherein the heating zone is offset towards the upstreamportion of the web-support surface along the pinch zone.
 16. Theprotective packaging formation device of claim of claim 11, whereinsealing mechanism includes a compression element that opposes thesupport surface, which forms a substantially stationary surface againstwhich the web material is pressured by the opposing compression element.17. The protective packaging formation device of claim 16, wherein theopposing compression member is a belt that forms a portion of the drivemechanism.
 18. The protective packaging formation device of claim 11,wherein a heater extends from one electrically conductive support to theother and is electrically connected to each.
 19. The protectivepackaging formation device of claim 18, wherein the heater is a thinfilm heater that follows the support surface.
 20. The protectivepackaging formation device of claim 19, wherein the thin film includes ahigh heat zone that is laid over the insulating member and a low heatzone located along at least one of the electrically conductive supports.21. The protective packaging formation device of claim 20, wherein theheat zone is defined by a length of the thin film heater that has afirst longitudinal portion with a reduced cross-section that outputssufficient heat to heat seal the web material and a second longitudinalportion wider than the first longitudinal portion having a reduced heatoutput and configured to gradually cool the sealed web material.
 22. Theprotective packaging formation device of claim 11, wherein at least oneof the electrically conductive supports includes a tension lever thatrotates relative thereto.
 23. The protective packaging formation deviceof claim 22, wherein a thin film heater is connected to the tensionlever, which places a biasing force away from the opposing connection ofthe thin film heater keeping the thin film heater in tension around thesupport surface.
 24. The protective packaging formation device of claim23, wherein the web is separated from the heater by at least one of alow friction belt or a low friction barrier.